3D-Printed Abrasive Articles With Compacted Powder Layers
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Solution Overview
Problem
Existing abrasive articles formed via additive manufacturing are limited in size, quantity, and quality, particularly in scaling from lab-scale to commercial scale, due to challenges in creating dense parts, dimensional stability, and understanding process variables such as powder composition, flowability, compaction force, and binder saturation, leading to inefficiencies and waste with raw material utilization.
Innovation Solution
A method involving dry powder layering and binding techniques using a bi-modal particle distribution of abrasive particles and bond material, with controlled compaction and binder application, followed by recycling of depowdered powder to improve manufacturability and quality, and manipulating printhead deposition resolution to enhance surface texture and interfacial area ratio (Sdr) for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing is used to form abrasive articles, then manufacturing flexibility and complexity are improved, but manufacturing precision and part density deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-compacting the powder layer before binder deposition and pre-heating the build plate to control powder flow and binder curing. The powder is compacted to a specific density range (0.4-0.6 g/cm³) before binding to ensure proper green body formation and prevent defects during sintering
Solution Approach 2:
The patent utilizes parameter changes by controlling binder saturation (0.1-0.5 volume ratio), build plate temperature (20-100°C), and compaction force to optimize the additive manufacturing process. These parameter adjustments enable precise control over part density and quality while maintaining manufacturing flexibility
2Manufacturing precision
If binder saturation is increased to improve green body strength, then manufacturing precision improves, but loss of substance increases due to binder material consumption
Solution Approach 1:
The patent implements feedback by monitoring binder deposition quantity and adjusting subsequent layers based on green body strength requirements. The binder is deposited to achieve specific saturation levels (0.1-0.5 volume ratio), and unused binder is recovered and reused, creating a closed-loop system that reduces waste while maintaining strength
Solution Approach 2:
The patent applies discarding and recovering by collecting and reusing unused binder material and depowdered abrasive particles. The binder recovery system captures excess binder for reuse in subsequent builds, and the depowdered abrasive is recycled into the powder feedstock, significantly reducing material consumption
3Manufacturing precision
If compaction force is increased to improve layer density, then manufacturing precision improves, but device complexity increases due to additional compaction equipment
Solution Approach 1:
The patent merges the compaction function with the existing powder spreading mechanism. The same roller or blade that spreads the powder layer also applies compaction force, eliminating the need for separate compaction equipment. This integrated approach achieves layer density of 0.4-0.6 g/cm³ without increasing device complexity
Solution Approach 2:
The patent applies universality by designing the powder delivery system to perform multiple functions: powder spreading, compaction, and surface smoothing. This multi-functional approach simplifies the overall device architecture while maintaining precise control over layer density and uniformity
Data Source
AI summary
A method for forming an abrasive article via an additive manufacturing technique including forming a layer of powder material comprising a precursor bond material and abrasive particles, compacting at least a portion of the layer to form a compacted layer, binding at least a portion of the compacted layer and repeating the steps of forming, compacting and binding to form a green body abrasive article.